Foldable electrical connector-housing system and method of manufacture thereof

ABSTRACT

A method of manufacture of a foldable electrical connector-housing system includes: providing a first end panel having an outer first end panel side with first end panel contacts that substantially span from one edge of the outer first end panel side to an opposite edge of the outer first end panel side; providing a second end panel having an outer second end panel side, the second end panel and the first end panel with the outer second end panel side facing away from the outer first end panel side and the first end panel contacts exposed in a folded configuration; mounting an electronic component between the outer first end panel side and the outer second end panel side; and connecting a conductor to the first end panel contacts and the electronic component.

CROSS-REFERENCE TO RELATED APPLICATION(S)

This is a continuation of co-pending U.S. patent application Ser. No.12/583,251 filed Aug. 17, 2009, which claims the benefit of U.S.Provisional Patent Application Ser. No. 61/089,494 filed Aug. 15, 2008,and the subject matter thereof is incorporated herein by referencethereto.

TECHNICAL FIELD

The present invention relates generally to an electrical housing, andmore particularly, to system for an electrical connector with a housingof minimal thickness.

BACKGROUND ART

Products must compete in world markets and attract many consumers orbuyers in order to be successful. A number of manufacturers produceelectronic systems, such as Flash based media (e.g. storage, MP3players, etc.), in credit card style or smaller sizes. There are manyproblems associated with these electronic systems that are size related.A considerable amount of effort has been applied to solving this issue.

One problem with these systems is electrical connection related. Forexample, a flash drive (or MP3 player, etc.) requires a Universal SerialBus (USB) electrical connection. A standard USB connection requires aconnector that is approximately 12 mm×2 mm in size. There are othermale-female type of connectors used as well.

The desired outcome of being able to store an electronic device with aUSB connector in a small personal space becomes hindered as thicknessand rigidity of the housing body make it difficult to fit in a smallpersonal space.

In addition, current solutions have additional bulk and rigidity thatmake carrying in a small personal space (like a typical American wallet)less convenient than the more pliable credit card.

One solution has been to provide a 2 mm thick card with a protruding“arm” containing contacts that act as the male side of a USB connector.However, this provides a bulky housing and potentially a relativelyfragile connector that “sticks out”.

Other solutions have been proposed that maintain the card shape andexpose the male connector by folding, pivoting, or sliding out a portionof the card. All these solutions require that some portion of thehousing be of sufficient thickness to mate with a USB female connector.

The standard size for credit cards, business cards, etc is about 55mm×85 mm×1 mm which is incompatible with a female USB connector.

Thus, a need exists to create an electrical housing compatible withsmall personal spaces, such as wallets and the like. In view of theever-increasing commercial competitive pressures and consumerexpectation, it is critical that answers be found for these problems.Additionally, the need to reduce costs, improve efficiencies andperformance, and meet competitive pressures adds an even greater urgencyto the critical necessity for finding answers to these problems.

Solutions to these problems have been long sought after but priordevelopments have not taught or suggested any solutions and, thus,solutions to these problems have long eluded those skilled in the art.

DISCLOSURE OF THE INVENTION

The present invention provides a method of manufacture of a foldableelectrical connector-housing system including: providing a first endpanel having an outer first end panel side with first end panel contactsthat substantially span from one edge of the outer first end panel sideto an opposite edge of the outer first end panel side; providing asecond end panel having an outer second end panel side, the second endpanel and the first end panel with the outer second end panel sidefacing away from the outer first end panel side and the first end panelcontacts exposed in a folded configuration; mounting an electroniccomponent between the outer first end panel side and the outer secondend panel side; and connecting a conductor to the first end panelcontacts and the electronic component.

The present invention provides a foldable electrical connector-housingsystem including: a first end panel having an outer first end panel sidewith first end panel contacts that substantially span from one edge ofthe outer first end panel side to an opposite edge of the outer firstend panel side; a second end panel having an outer second end panelside, the second end panel and the first end panel with the outer secondend panel side facing away from the outer first end panel side and thefirst end panel contacts exposed in a folded configuration; anelectronic component mounted between the outer first end panel side andthe outer second end panel side; and a conductor connected to the firstend panel contacts and the electronic component.

Certain embodiments of the invention have other steps or elements inaddition to or in place of those mentioned above. The steps or elementswill become apparent to those skilled in the art from a reading of thefollowing detailed description when taken with reference to theaccompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is an orthogonal view of a foldable electrical connector-housingsystem in an open configuration of a first embodiment of the presentinvention.

FIG. 2 is the structure of FIG. 1 in a partially folded configuration.

FIG. 3 is the structure of FIG. 1 in a folded configuration.

FIG. 4 is an orthogonal view of a foldable electrical connector-housingsystem in an open configuration of a second embodiment of the presentinvention.

FIG. 5 is the structure of FIG. 4 in a partially folded configuration.

FIG. 6 is the structure of FIG. 4 in a folded configuration.

FIG. 7 is an orthogonal view of a foldable electrical connector-housingsystem in an open configuration of a third embodiment of the presentinvention.

FIG. 8 is the structure of FIG. 7 in a partially folded configuration.

FIG. 9 is the structure of FIG. 7 in a folded configuration.

FIG. 10 is an orthogonal view of a foldable electrical connector-housingsystem in an open configuration of a fourth embodiment of the presentinvention.

FIG. 11 is the structure of FIG. 10 in a partially folded configuration.

FIG. 12 is the structure of FIG. 10 in a folded configuration.

FIG. 13 is an orthogonal view of a foldable electrical connector-housingsystem in an open configuration of a fifth embodiment of the presentinvention.

FIG. 14 is the structure of FIG. 13 in a partially folded configuration.

FIG. 15 is the structure of FIG. 13 in a folded configuration.

FIG. 16 is an orthogonal view of a foldable electrical connector-housingsystem in an open configuration of a sixth embodiment of the presentinvention.

FIG. 17 is the structure of FIG. 16 in a partially folded configuration.

FIG. 18 is the structure of FIG. 16 in a folded configuration.

FIG. 19 is a top plan view of the foldable electrical connector-housingsystem in an open configuration.

FIG. 20 is a cross-sectional view of FIG. 19 taken along a line 20-20 ofFIG. 19.

FIG. 21 is a cross-sectional view of the structure of FIG. 20 in aconnection phase.

FIG. 22 is a flow chart of a method of manufacture of a foldableelectrical connector-housing system in a further embodiment of thepresent invention.

BEST MODE FOR CARRYING OUT THE INVENTION

The following embodiments are described in sufficient detail to enablethose skilled in the art to make and use the invention. It is to beunderstood that other embodiments would be evident based on the presentdisclosure, and that system, process, or mechanical changes may be madewithout departing from the scope of the present invention.

In the following description, numerous specific details are given toprovide a thorough understanding of the invention. However, it will beapparent that the invention may be practiced without these specificdetails. In order to avoid obscuring the present invention, somewell-known circuits, system configurations, and process steps are notdisclosed in detail.

The drawings showing embodiments of the system are semi-diagrammatic andnot to scale and, particularly, some of the dimensions are for theclarity of presentation and are shown greatly exaggerated in the drawingFIGs. Similarly, although the views in the drawings shown for ease ofdescription and generally show similar orientations, this depiction inthe FIGs. is arbitrary for the most part. Generally, the invention canbe operated in any orientation.

Where multiple embodiments are disclosed and described having somefeatures in common, for clarity and ease of illustration, description,and comprehension thereof, similar and like features one to another willordinarily be described with similar reference numerals. The embodimentshave been numbered first embodiment, second embodiment, etc. as a matterof descriptive convenience and are not intended to have any othersignificance or provide limitations for the present invention.

For expository purposes, the term “horizontal” as used herein is definedas a plane parallel to the plane or surface of the present invention,regardless of its orientation. The term “vertical” refers to a directionperpendicular to the horizontal as just defined. Terms, such as “above”,“below”, “bottom”, “top”, “side” (as in “sidewall”), “higher”, “lower”,“upper”, “over”, and “under”, are defined with respect to the horizontalplane. The term “on” means that there is direct contact among elements.

The term “active side” refers to a side of a die, a module, a package,or an electronic structure having active circuitry fabricated thereon orhaving elements for connection to the active circuitry within the die,the module, the package, or the electronic structure. The term“processing” as used herein includes deposition of material orphotoresist, patterning, exposure, development, etching, cleaning,and/or removal of the material or photoresist as required in forming adescribed structure.

Referring now to FIG. 1, therein is shown an orthogonal view of afoldable electrical connector-housing system 100 in an openconfiguration of a first embodiment of the present invention. The openconfiguration can be used for transporting or storing of the foldableelectrical connector-housing system 100.

The present embodiment can preferably include a first end panel 102, asecond end panel 104, and a fold mechanism 106. The first end panel 102,such as a panel, leaf, or board, can be formed from a non-conductivematerial having a rigid, a semi-pliable, a flexible, or a combination ofcharacteristics thereof. The first end panel 102 can include apredetermined thickness based on user requirements such as physicalconstraints, product features, or production needs. The first end panel102 is coupled to the second end panel 104 with the fold mechanism 106.

The second end panel 104 can be similar to the first end panel 102. Thesecond end panel 104 can include a predetermined thickness identical ordifferent from the predetermined thickness of the first end panel 102.The predetermined thickness of the second end panel 104 is chosen tomeet specific requirements of the user such as physical constraints,product features, or production needs.

For purposes of illustration, the first end panel 102 and the second endpanel 104 are shown in a shape of a rectangle although the first endpanel 102 or the second end panel 104 may be of any shape, size ordifferent from one another.

First end panel contacts 114 of the first end panel 102 can be formedcompletely on the first end panel 102 and substantially span from oneedge of an outer first end panel side 112 to an opposite edge of theouter first end panel side 112. The first end panel contacts 114 canprovide electrical connectivity to an electronic component, such asmemory circuitry, and an external connector, subsystem, or system.

The outer first end panel side 112 of the first end panel 102 canpreferably include the first end panel contacts 114, such as leadfingers, pads, balls, or bumps, substantially exposed on and coplanarwith the outer first end panel side 112. The first end panel contacts114 can preferably be formed closest to a short first end edge 116 ofthe first end panel.

For purposes of illustration, the first end panel contacts 114 are shownnext to one edge of the outer first end panel side 112, although thefirst end panel contacts 114 can be of any number, in any location, onany side, in any number of locations, next to any edge, or have aspacing from any edge.

The fold mechanism 106 such as a hinge, live-hinge, flexible section, orpreformed region, can be formed as a discrete part, integral to thefirst end panel 102, integral to the second end panel 104, orcombination thereof. The fold mechanism 106 can be directly attached toan edge of the first end panel 102 and an edge of the second end panel104 to provide rotation of both the first end panel 102 and the secondend panel 104 about the fold mechanism 106.

The rotation of both the first end panel 102 and the second end panel104 can provide the outer first end panel side 112 facing away from anouter second end panel side 118. For example, when folded, the outerfirst end panel side 112 and the outer second end panel side 118 can besubstantially exposed and opposite one another.

Furthermore, for example, the fold mechanism 106 can be provided on along first end edge 124 of the first end panel 102 and a long second endedge 126 of the second end panel 104.

The first end panel 102 and the second end panel 104 can be folded orrotated at the fold mechanism 106 around a central axis line or foldaxis line formed along a length of the fold mechanism 106 and canoptionally include at least one pin (not shown) such as flexible pin orrigid pin. The pin can preferably be small enough to ensure that anyintended rotational movement is substantially unobstructed.

In the open configuration, a plane of the outer first end panel side 112can be substantially coplanar to a plane of the outer second end panelside 118. Thus, the outer first end panel side 112 and the outer secondend panel side 118 can form a substantially flat surface. Thesubstantially flat surface can optionally be printed, labeled, orstamped with images or text.

The present invention can optionally include a spacer 128 such as panelstrips, posts, or borders preferably formed of non-conductive material.The spacer 128 can be provided with the first end panel 102 to extendthe side opposite the outer first end panel side 112.

The spacer 128 can provide added protection to devices when in the openconfiguration. The spacer 128 can also separate the first end panel 102from the second end panel 104 when the present invention is folded orinserted into a mating connector.

It has been discovered that one set of the first end panel contacts 114can be included next to one of the short first end edge 116 and anotherset of the first end panel contacts 114 can be included next to anotherof the short first end edge 116.

Referring now to FIG. 2, therein is shown the structure of FIG. 1 in apartially folded configuration. The partially folded configurationprovides the present invention in a transitional phase, such as duringrepositioning of the first end panel 102 and the second end panel 104from the opened configuration to a closed configuration or vice-versa.

The present invention in the partially folded configuration includescharacteristics of the first end panel 102 forming an obtuse, right, oracute angle with the second end panel 104 and with the outer first endpanel side 112 of the first end panel 102 facing away from the secondend panel 104.

The first end panel 102 and the second end panel 104 can preferably foldalong the fold mechanism 106 connecting both the first end panel 102 andthe second end panel 104. Folding such as half folding can provide thefirst end panel contacts 114 substantially exposed. The partially foldedconfiguration substantially eliminates direct physical contact betweenthe first end panel 102 and the second end panel 104.

Referring now to FIG. 3, therein is shown the structure of FIG. 1 in afolded configuration. The folded configuration provides the panelssubstantially parallel and substantially eliminates spacing betweenpanels or spacers to form a connector-housing.

The first end panel contacts 114 can be substantially exposed to provideconnectivity to mating connectors of an electronic subsystem or systemsuch as a computer, security system, data storage facility, or anyelectronic system having a connector.

For example, the first end panel contacts 114 can be compatible with afemale USB port. Further folding the foldable electricalconnector-housing system 100 can create a male USB connector. The foldedconfiguration includes a combined thickness that can provide joiningwith a mating connector such as forming a male connector that is capableof joining with a female connector.

It has been discovered that the present invention with a holdingmechanism (not shown) to hold panels or leaves together can also form afemale connector for insertion of a male connector of another electronicsystem or the present invention. The female connector such as anopening, cavity, or hole can provide connectivity or registration forcompatibility with mating connectors having protrusions.

It has been found that in another folded configuration, the presentinvention can be folded with the first end panel contacts 114 directlyfacing the outer second end panel side 118 for protection of the firstend panel contacts 114.

Referring now to FIG. 4, therein is shown an orthogonal view of afoldable electrical connector-housing system 400 in an openconfiguration of a second embodiment of the present invention. The openconfiguration can be used for transporting or storing of the foldableelectrical connector-housing system 400.

The present embodiment can preferably include a first end panel 402, asecond end panel 404, and a fold mechanism 406. The first end panel 402,such as a panel, leaf, or board, can be formed from a non-conductivematerial having a rigid, a semi-pliable, a flexible, or a combination ofcharacteristics thereof. The first end panel 402 can include apredetermined thickness based on user requirements such as physicalconstraints, product features, or production needs.

Similarly, the present invention can include the second end panel 404.The second end panel 404 can include a predetermined thickness identicalor different from the predetermined thickness of the first end panel402. The predetermined thickness of the second end panel 404 is chosento meet specific requirements of the user such as physical constraints,product features, or production needs.

The fold mechanism 406 such as a hinge, live-hinge, flexible section, orpreformed region, can be formed as a discrete part, integral to thefirst end panel 402, integral to the second end panel 404, orcombination thereof. The fold mechanism 406 can be directly attached toan edge of the first end panel 402 and an edge of the second end panel404 to provide rotation of both the first end panel 402 and the secondend panel 404 about the fold mechanism 406.

The first end panel 402 and the second end panel 404 can be folded orrotated at the fold mechanism 406 around a central axis line or foldaxis line formed along a length of the fold mechanism 406 and canoptionally include at least one pin (not shown) such as flexible pin orrigid pin. The pin can preferably be small enough to ensure that anyintended rotational movement is substantially unobstructed.

An outer first end panel side 412 of the first end panel 402 canpreferably include first end panel contacts 414, such as lead fingers,pads, balls, or bumps, substantially exposed on and coplanar with theouter first end panel side 412. The first end panel contacts 414 cansubstantially span from one edge of the outer first end panel side 412to an opposite edge of the outer first end panel side 412.

The first end panel contacts 414 can be formed closest to a short firstend edge 416 of the first end panel 402. The first end panel contacts414 can provide electrical connectivity to memory circuitry and anexternal connector, subsystem, or system.

Similarly, an outer second end panel side 418 of the second end panel404 can preferably include second end panel contacts 420, such as leadfingers, pads, balls, or bumps, substantially exposed on and coplanarwith the outer first end panel side 412. The second end panel contacts420 can substantially span from one edge of the outer second end panelside 418 to an opposite edge of the outer second end panel side 418.

The second end panel contacts 420 can be formed closest to a shortsecond end edge 422 of the second end panel 404. The second end panelcontacts 420 can provide electrical connectivity to memory circuitry andan external connector, subsystem, or system.

The short first end edge 416 with the first end panel contacts 414 canbe adjacent a long first end edge 424 that can attach to or include aportion of the fold mechanism 406. Similarly, the short second end edge422 with the second end panel contacts 420 can be adjacent a long secondend edge 426 that can attach to or include a portion of the foldmechanism 406.

The foldable electrical connector-housing system 400 can be formed withtwo panels in an open position and panel contacts on two panels so as toallow connecting to a female connector in either of two orientations.

Referring now to FIG. 5, therein is shown the structure of FIG. 4 in apartially folded configuration. The partially folded configurationprovides the present invention in a transitional phase, such as duringrepositioning of the first end panel 402 and the second end panel 404from the opened configuration to a closed configuration or vice-versa.

The present invention in the partially folded configuration includescharacteristics of the first end panel 402 forming an obtuse, right, oracute angle with the second end panel 404 and with the outer first endpanel side 412 of the first end panel 402 facing away from the outersecond end panel side 418 of the second end panel 404.

The first end panel 402 and the second end panel 404 can preferably foldalong the fold mechanism 406 connecting both the first end panel 402 andthe second end panel 404. Folding such as half folding can provide thefirst end panel contacts 414 or the second end panel contacts 420substantially exposed.

Referring now to FIG. 6, therein is shown the structure of FIG. 4 in afolded configuration. The folded configuration provides the panelssubstantially parallel and substantially eliminates spacing betweenpanels to form a connector-housing.

The first end panel contacts 414 and the second end panel contacts 420of FIG. 5 can be substantially exposed to provide connectivity to matingconnectors of an electronic subsystem or system such as a computer,security system, data storage facility, or any electronic system havinga connector.

A connector width 602 or a connector thickness 604 of the presentinvention can be selected to ensure that the present invention can beinserted in the mating connectors of the various electronic systems.

The connector thickness 604 can be defined as a distance from the outerfirst end panel side 412 to the outer second end panel side 418 of FIG.5. The connector thickness 604 can also include a spacer height 606predetermined for providing structural protection such as a crushprotection and proper overall dimensional thickness of the foldableelectrical connector-housing system 400.

The connector width 602 can be defined as the summation of the width ofa panel with any measurable portion of the fold mechanism 406 extendingaway from an edge of a panel closest to the fold mechanism 406. Theconnector width 602 or the connector thickness 604 of the presentinvention can be predetermined to ensure that the present invention canbe inserted in the mating connectors of the various electronic systems.

For example, the connector thickness 604 with panels havingsubstantially uniform thickness can be calculated using the followingformula:

CT=(1+N)*MT

where CT=the connector thickness 604, N=the number of folds, and MT=thematerial thickness of each panel.

For example, a flash drive requires a Universal Serial Bus (USB)electrical connection. A USB connection requires a connector that isapproximately 12 mm×2 mm in size. It has been discovered that by foldinga credit card-sized foldable electrical connector-housing system, whichis approximately 48 mm×85 mm×0.50 mm, at three flexible hinge locations,a proper thickness USB connector may be formed.

The foldable electrical connector-housing system 400 can be folded andconnected to a female USB connector in accordance with variousembodiments of the present invention. The foldable electricalconnector-housing system 400 can be composed of two leaves that areshown in a juxtaposed position in the folded state. The combinedthickness of the two leaves make it compatible with the receptacle of afemale connector. The desired thickness creates enough pressure, wheninserted, to press the first end panel contacts 414 or the second endpanel contacts 420 against connectors of the female connector.

Referring now to FIG. 7, therein is shown an orthogonal view of afoldable electrical connector-housing system 700 in an openconfiguration of a third embodiment of the present invention. The openconfiguration can be used for transporting or storing of the foldableelectrical connector-housing system 700.

The present invention in the open configuration can provide planardimensions similar to a current credit card of approximately 85millimeters by 54 millimeters. The planar dimensions in the openconfiguration can preferably allow the present invention to fit into awallet with other credit cards or similar cards.

The present embodiment can preferably include a first end panel 702, asecond end panel 704, and a fold mechanism 706. The first end panel 702,such as a panel, leaf, or board, can be formed from a non-conductivematerial having a rigid, a semi-pliable, a flexible, or a combination ofcharacteristics thereof. The first end panel 702 can include apredetermined thickness based on user requirements such as physicalconstraints, product features, or production needs.

Similarly, the present invention can include the second end panel 704.The second end panel 704 can include a predetermined thickness identicalor different from the predetermined thickness of the first end panel702. The predetermined thickness of the second end panel 704 is chosento meet specific requirements of the user such as physical constraints,product features, or production needs.

The fold mechanism 706 such as a hinge, flexible section, or preformedregion, can be formed as a discrete part, integral to any panel, orcombination thereof. The fold mechanism 706 can be directly attached toan edge of a panel and an edge of an adjacent panel to provide rotationof the panel and the adjacent panel about the fold mechanism 706.

A spacer panel 708 can have any shape or size including substantiallythe same planar shape as the second end panel 704 or the first end panel702. The fold mechanism 706 can be attached to the spacer panel 708 andthe first end panel 702. Another of the fold mechanism 706 can beattached to a side of the spacer panel 708 opposite the first end panel702 and the second end panel 704.

An outer first end panel side 712 of the first end panel 702 canpreferably include first end panel contacts 714, such as lead fingers,pads, balls, or bumps, substantially exposed on and coplanar with theouter first end panel side 712. The first end panel contacts 714 cansubstantially span from one edge of the outer first end panel side 712to an opposite edge of the outer first end panel side 712.

The first end panel contacts 714 can be formed closest to a short firstend edge 716 of the first end panel 702. The first end panel contacts714 can provide electrical connectivity to memory circuitry and anexternal connector, subsystem, or system.

Similarly, the second end panel 704 can preferably include an outersecond end panel side 718, the outer second end panel side 718 is shownbehind the second end panel 704. The outer second end panel side 718 canpreferably include second end panel contacts 720, such as lead fingers,pads, balls, or bumps, shown as hidden lines on the outer second endpanel side 718. The second end panel contacts 720 can be exposed on andcoplanar with the outer second end panel side 718 of the second endpanel 704.

The second end panel contacts 720 can substantially span from one edgeof the outer second end panel side 718 to an opposite edge of the outersecond end panel side 718. The second end panel contacts 720 can beformed closest to a short second end edge 722 of the second end panel704. The second end panel contacts 720 can provide electricalconnectivity to memory circuitry and an external connector, subsystem,or system.

The short first end edge 716 with the first end panel contacts 714 canbe adjacent a long first end edge 724 that can attach to or include aportion of the fold mechanism 706. Similarly, the short second end edge722 with the second end panel contacts 720 can be adjacent a long secondend edge 726 that can attach to or include a portion of another of thefold mechanism 706.

Long spacer edges 728 can be formed on opposite sides of the spacerpanel 708. The long spacer edges 728 can attach to or include portionsof the fold mechanism 706 for attachment to the first end panel 702 orthe second end panel 704.

Referring now to FIG. 8, therein is shown the structure of FIG. 7 in apartially folded configuration. The partially folded configurationprovides the present invention in a transitional phase, such as duringrepositioning of the first end panel 702, the spacer panel 708, and thesecond end panel 704 from the opened configuration to a closedconfiguration or vice-versa.

The present invention in the partially folded configuration includescharacteristics of the first end panel 702, the spacer panel 708, or thesecond end panel 704 forming an obtuse, right, or acute angle with oneanother.

The first end panel 702, the spacer panel 708, and the second end panel704 can preferably fold along each of a plurality of the fold mechanism706 connecting the first end panel 702, the spacer panel 708, or thesecond end panel 704. Folding such as alternate folding or fan foldingcan provide the first end panel contacts 714 or the second end panelcontacts 720 substantially exposed.

Referring now to FIG. 9, therein is shown the structure of FIG. 7 in afolded configuration. The folded configuration provides the panelssubstantially parallel and substantially eliminates spacing betweenpanels to form a connector-housing.

The first end panel contacts 714 and the second end panel contacts 720of FIG. 8 can be substantially exposed to provide connectivity to matingconnectors of an electronic subsystem or system such as a computer,security system, data storage facility, or any electronic system havinga connector.

Referring now to FIG. 10, therein is shown an orthogonal view of afoldable electrical connector-housing system 1000 in an openconfiguration of a fourth embodiment of the present invention. The openconfiguration can be used for transporting or storing of the foldableelectrical connector-housing system 1000.

The present embodiment can preferably include a first end panel 1002, asecond end panel 1004, and a fold mechanism 1006. The first end panel1002, such as a panel, leaf, or board, can be formed from anon-conductive material having a rigid, a semi-pliable, a flexible, or acombination of characteristics thereof. The first end panel 1002 caninclude a predetermined thickness based on user requirements such asphysical constraints, product features, or production needs.

Similarly, the present invention can include the second end panel 1004.The second end panel 1004 can include a predetermined thicknessidentical or different from the predetermined thickness of the first endpanel 1002. The predetermined thickness of the second end panel 1004 ischosen to meet specific requirements of the user such as physicalconstraints, product features, or production needs.

The fold mechanism 1006 such as a hinge, flexible section, or preformedregion, can be formed as a discrete part, integral to any panel, orcombination thereof. The fold mechanism 1006 can be directly attached toan edge of a panel and an edge of an adjacent panel to provide rotationof the panel and the adjacent panel about the fold mechanism 1006.

A first end spacer panel 1008 or a second end spacer panel 1010 can haveany shape or size including substantially the same planar shape as thesecond end panel 1004 or the first end panel 1002. The fold mechanism1006 can be attached to the first end spacer panel 1008 and the firstend panel 1002. Another of the fold mechanism 1006 can be attached tothe first end spacer panel 1008 and the second end spacer panel 1010.Yet another of the fold mechanism 1006 can be attached to a side of thesecond end spacer panel 1010 and the second end panel 1004.

An outer first end panel side 1012 of the first end panel 1002 canpreferably include first end panel contacts 1014, such as lead fingers,pads, balls, or bumps, substantially exposed on and coplanar with theouter first end panel side 1012. The first end panel contacts 1014 cansubstantially span from one edge of the outer first end panel side 1012to an opposite edge of the outer first end panel side 1012.

The first end panel contacts 1014 can be formed closest to a short firstend edge 1016 of the first end panel 1002. The first end panel contacts1014 can provide electrical connectivity to memory circuitry and anexternal connector, subsystem, or system.

Similarly, the second end panel 1004 can preferably include second endpanel contacts 1020 on an outer second end panel side 1018 of the secondend panel 1004. The second end panel contacts 1020 can be exposed on andcoplanar with a side of the second end panel 1004. The second end panelcontacts 1020, such as lead fingers, pads, balls, or bumps, cansubstantially span from one edge of the outer second end panel side 1018to an opposite edge of the outer second end panel side 1018.

The second end panel contacts 1020 can be formed closest to a shortsecond end edge 1022 of the second end panel 1004. The second end panelcontacts 1020 can provide electrical connectivity to memory circuitryand an external connector, subsystem, or system.

The short first end edge 1016 with the first end panel contacts 1014 canbe adjacent a long first end edge 1024 that can attach to or include aportion of the fold mechanism 1006. Similarly, the short second end edge1022 with the second end panel contacts 1020 can be adjacent a longsecond end edge 1026 that can attach to or include a portion of anotherof the fold mechanism 1006.

First end long spacer edges 1028 can be formed on opposite sides of thefirst end spacer panel 1008. The first end long spacer edges 1028 canattach to or include portions of the fold mechanism 1006 for attachmentto the first end panel 1002 or the second end spacer panel 1010.Similarly, second end long spacer edges 1030 can be formed on oppositesides of the second end spacer panel 1010 and can attach to or includeportions of the fold mechanism 1006 for attachment to the second endpanel 1004 or the first end spacer panel 1008.

For purposes of illustration, the foldable electrical connector-housingsystem 1000 is shown having four panels although it is understood thatany number of panels may be used.

Referring now to FIG. 11, therein is shown structure of FIG. 10 in apartially folded configuration. The partially folded configuration canbe identified when an obtuse, a right, or an acute angle can be formedbetween the first end panel 1002 and the first end spacer panel 1008,the second end spacer panel 1010, or the second end panel 1004.

The present invention in the partially folded configuration includescharacteristics of the first end panel 1002, the first end spacer panel1008, the second end spacer panel 1010, or the second end panel 1004forming an obtuse, right, or acute angle with one another.

The first end panel 1002, the first end spacer panel 1008, the secondend spacer panel 1010, and the second end panel 1004 can preferably foldalong each of a plurality of the fold mechanism 1006 connecting thefirst end panel 1002, the first end spacer panel 1008, the second endspacer panel 1010, or the second end panel 1004. Folding such asalternate folding or fan folding can provide the first end panelcontacts 1014 or the second end panel contacts 1020 substantiallyexposed.

Referring now to FIG. 12, therein is shown the structure of FIG. 10 in afolded configuration. The folded configuration provides the panelssubstantially parallel and substantially eliminates spacing betweenpanels to form a connector-housing.

The first end panel contacts 1014 and the second end panel contacts 1020of FIG. 11 can be substantially exposed to provide connectivity tomating connectors of an electronic subsystem or system such as acomputer, security system, data storage facility, or any electronicsystem having a connector.

It has been found that sides of the first end panel 1002, the first endspacer panel 1008, the second end spacer panel 1010, the second endpanel 1004, or combination thereof can be printed with logos oradvertising material for advertising purposes.

Referring now to FIG. 13, therein is shown an orthogonal view of afoldable electrical connector-housing system 1300 in an openconfiguration of a fifth embodiment of the present invention. The openconfiguration can be used for transporting or storing of the foldableelectrical connector-housing system 1300.

The present embodiment can preferably include a first end panel 1302, asecond end panel 1304, and a fold mechanism 1306. The first end panel1302, such as a panel, leaf, or board, can be formed from anon-conductive material having a rigid, a semi-pliable, a flexible, or acombination of characteristics thereof. The first end panel 1302 caninclude a predetermined thickness based on user requirements such asphysical constraints, product features, or production needs.

Similarly, the present invention can include the second end panel 1304.The second end panel 1304 can include a predetermined thicknessidentical or different from the predetermined thickness of the first endpanel 1302. The predetermined thickness of the second end panel 1304 ischosen to meet specific requirements of the user such as physicalconstraints, product features, or production needs.

The fold mechanism 1306 such as a hinge, flexible section, or preformedregion, can be formed as a discrete part, integral to the first endpanel 1302, integral to the second end panel 1304, or combinationthereof. The fold mechanism 1306 can be directly attached to an edge ofthe first end panel 1302 and an edge of the second end panel 1304 toprovide rotation of both the first end panel 1302 and the second endpanel about the fold mechanism 1306.

The first end panel 1302 and the second end panel 1304 can be folded orrotated at the fold mechanism 1306 around a central axis line or foldaxis line formed along a length of the fold mechanism 1306 and canoptionally include at least one pin (not shown) such as flexible pin orrigid pin. The pin can preferably be small enough to ensure that anyintended rotational movement is substantially unobstructed.

An outer first end panel side 1312 of the first end panel 1302 canpreferably include first end panel contacts 1314, such as lead fingers,pads, balls, or bumps, substantially exposed on and coplanar with theouter first end panel side 1312. The first end panel contacts 1314 cansubstantially span from one edge of the outer first end panel side 1312to an opposite edge of the outer first end panel side 1312.

The first end panel contacts 1314 can be formed closest to a short firstend edge 1316 of the first end panel 1302. The first end panel contacts1314 can provide electrical connectivity to memory circuitry and anexternal connector, subsystem, or system.

Similarly, an outer second end panel side 1318 of the second end panel1304 can preferably include second end panel contacts 1320, such as leadfingers, pads, balls, or bumps, substantially exposed on and coplanarwith the outer first end panel side 1312. The second end panel contacts1320 (optional) can substantially span from one edge of the outer secondend panel side 1318 to an opposite edge of the outer second end panelside 1318.

Having the first end panel contacts 1314 and the second end panelcontacts 1320 on both sides (when folded) of the foldable electricalconnector-housing system 1300 may allow user to insert the presentinvention in the female USB connector on either side, which improvesusability (of course, grounding should be provided as well).

It is possible to have two flash drives embodied in a single package.Insertion with the outer first end panel side 1312 of the first endpanel 1302 facing up may make electrical contact with drive A of side A.Insertion with the outer second end panel 1318 of the second end panel1304 facing up may make electrical contact with drive B of side B.

The second end panel contacts 1320 can be formed closest to a shortsecond end edge 1322 of the second end panel 1304. The second end panelcontacts 1320 can provide electrical connectivity to memory circuitryand an external connector, subsystem, or system.

The short first end edge 1316 opposite the first end panel contacts 1314can attach to or include a portion of the fold mechanism 1306.Similarly, the short second end edge 1322 opposite the second end panelcontacts 1320 can attach to or include a portion of the fold mechanism1306.

Referring now to FIG. 14, therein is shown the structure of FIG. 13 in apartially folded configuration. The partially folded configurationprovides the present invention in a transitional phase, such as duringrepositioning of the first end panel 1302 and the second end panel 1304from the opened configuration to a closed configuration or vice-versa.

The present invention in the partially folded configuration includescharacteristics of the first end panel 1302 forming an obtuse, right, oracute angle with the second end panel 1304 and with the outer first endpanel side 1312 of the first end panel 1302 facing away from the outersecond end panel side 1318 of the second end panel 1304.

The first end panel 1302 and the second end panel 1304 can preferablyfold along the fold mechanism 1306 connecting both the first end panel1302 and the second end panel 1304. Folding such as half folding canprovide the first end panel contacts 1314 or the second end panelcontacts 1320 substantially exposed.

Referring now to FIG. 15, therein is shown the structure of FIG. 13 in afolded configuration. The folded configuration provides the panelssubstantially parallel and substantially eliminates spacing betweenpanels to form a connector-housing.

The first end panel contacts 1314 of FIG. 14 and the second end panelcontacts 1320 can be substantially exposed to provide connectivity tomating connectors of an electronic subsystem or system such as acomputer, security system, data storage facility, or any electronicsystem having a connector.

Referring now to FIG. 16, therein is shown an orthogonal view of afoldable electrical connector-housing system 1600 in an openconfiguration of a sixth embodiment of the present invention. The openconfiguration can be used for transporting or storing of the foldableelectrical connector-housing system 1600.

The present embodiment can preferably include a first end panel 1602, asecond end panel 1604, and a fold mechanism 1606. The first end panel1602, such as a panel, leaf, or board, can be formed from anon-conductive material having a rigid, a semi-pliable, a flexible, or acombination of characteristics thereof. The first end panel 1602 caninclude a predetermined thickness based on user requirements such asphysical constraints, product features, or production needs.

Similarly, the present invention can include the second end panel 1604.The second end panel 1604 can include a predetermined thicknessidentical or different from the predetermined thickness of the first endpanel 1602. The predetermined thickness of the second end panel 1604 ischosen to meet specific requirements of the user such as physicalconstraints, product features, or production needs.

The fold mechanism 1606 such as a hinge, flexible section, or preformedregion, can be formed as a discrete part, integral to the first endpanel 1602, integral to the second end panel 1604, or combinationthereof. The fold mechanism 1606 can be directly attached to an edge ofthe first end panel 1602 and an edge of the second end panel 1604 toprovide rotation of both the first end panel 1602 and the second endpanel about the fold mechanism 1606.

The first end panel 1602 and the second end panel 1604 can be folded orrotated at the fold mechanism 1606 around a central axis line or foldaxis line formed along a length of the fold mechanism 1606 and canoptionally include at least one pin (not shown) such as flexible pin orrigid pin. The pin can preferably be small enough to ensure that anyintended rotational movement is substantially unobstructed.

An outer first end panel side 1612 of the first end panel 1602 canpreferably include first end panel contacts 1614, such as lead fingers,pads, balls, or bumps, substantially exposed on and coplanar with theouter first end panel side 1612. The first end panel contacts 1614 cansubstantially span from one edge of the outer first end panel side 1612to an opposite edge of the outer first end panel side 1612.

The first end panel contacts 1614 can be formed closest to a short firstend edge 1616 of the first end panel 1602. The first end panel contacts1614 can provide electrical connectivity to memory circuitry and anexternal connector, subsystem, or system.

Similarly, an outer second end panel side 1618 of the second end panel1604 can preferably include second end panel contacts 1620 (optional),such as lead fingers, pads, balls, or bumps, substantially exposed onand coplanar with the outer first end panel side 1612. The second endpanel contacts 1620 can substantially span from one edge of the outersecond end panel side 1618 to an opposite edge of the outer second endpanel side 1618. As above, having connectors on both sides (when folded)may allow insertion of the folded male connector right side up or upside down, which improves usability.

The second end panel contacts 1620 can be formed closest to a shortsecond end edge 1622 of the second end panel 1604. The first end panelcontacts 1614 can provide electrical connectivity to memory circuitryand an external connector, subsystem, or system.

The short first end edge 1616 next to the first end panel contacts 1614can attach to or include a portion of the fold mechanism 1606.Similarly, the short second end edge 1622 next to the second end panelcontacts 1620 can attach to or include a portion of the fold mechanism1606.

Referring now to FIG. 17, therein is shown the structure of FIG. 16 in apartially folded configuration. The partially folded configurationprovides the present invention in a transitional phase, such as duringrepositioning of the first end panel 1602 and the second end panel 1604from the opened configuration to a closed configuration or vice-versa.

The present invention in the partially folded configuration includescharacteristics of the first end panel 1602 forming an obtuse, right, oracute angle with the second end panel 1604 and with the outer first endpanel side 1612 of the first end panel 1602 facing away from the outersecond end panel side 1618 of the second end panel 1604.

The first end panel 1602 and the second end panel 1604 can preferablyfold along the fold mechanism 1606 connecting both the first end panel1602 and the second end panel 1604. Folding such as half folding canprovide the first end panel contacts 1614 or the second end panelcontacts 1620 substantially exposed.

Referring now to FIG. 18, therein is shown the structure of FIG. 16 in afolded configuration. The folded configuration provides the panelssubstantially parallel and substantially eliminates spacing betweenpanels to form a connector-housing.

The first end panel contacts 1614 of FIG. 17 and the second end panelcontacts 1620 can be substantially exposed to provide connectivity tomating connectors of an electronic subsystem or system such as acomputer, security system, data storage facility, or any electronicsystem having a connector.

Referring now to FIG. 19, therein is shown a top plan view of thefoldable electrical connector-housing system 100 in an openconfiguration. For example, the foldable electrical connector-housingsystem 100 can preferably include electronic components or memorycircuitry, shown with hidden lines, such as a controller 1902, a memorytiming control module 1904, and a memory device 1906.

The memory device 1906 such as a flash-memory, micro-disk, or othernon-volatile storage device can be electrically connected to thecontroller 1902, the memory timing control module 1904, or the first endpanel contacts 114. The memory device 1906 can provide storage for userdefined information.

Two or more sets of the memory circuitry can be used For example, thefoldable electrical connector-housing system may contain two flashdrives that might be organized so that one may be able to store businessrelated files and by flipping, another drive becomes available forstoring personal information. One side can optionally be labeled such as“business” and another side can optionally be labeled as “personal”.

The controller 1902, such as a memory controller or universal serial buscontroller, can control information such as dataflow, data format,operation of the memory device 1906, error handling/recovery, or powersequencing of the circuitry within the foldable electricalconnector-housing system 100.

The memory timing control module 1904 can generate, control, or monitorthe timing signals, such as clocks and clocking controls, required tomaintain proper synchronization and reliable operation of the memorycircuitry. In some embodiments, the memory timing control module 1904 isincorporated in the controller 1902.

Conductors 1908, shown with hidden lines, such as flexible wires,traces, strips, or any conductor can directly connect the controller1902, the memory timing control module 1904, the memory device 1906, orthe first end panel contacts 114 with one another.

For purposes of illustration, the memory device 1906 and the controller1902 are shown in the first end panel 102, although the memory device1906 and the controller 1902 may be in any panel or in any location oron the same panel.

Further for purposes of illustration, the memory timing control module1904 is shown in the second end panel 104, although the memory timingcontrol module 1904 may be in any panel or in any location or on thesame panel.

Also for purposes of illustration, the conductors 1908 are shown on orin the first end panel 102 or the second end panel 104, although all ora portion of the conductors 1908 may be formed over the first end panel102 or the second end panel 104 as an integral part of a printed circuitboard or substrate.

Electrical components 1910, such as the controller 1902, the memorytiming control module 1904, the memory device 1906, passive components,a power component such as a battery or a solar cell, or any othercomponent can be included on or within the foldable electricalconnector-housing system 100.

Functionally different or incompatible devices can be mounted inopposite sides or panels to provide a high reliability and availabilityversion (HRAV) or a dual functionality version (DFV).

Some or all of the electrical components 1910, for example thecontroller 1902, the memory timing control module 1904, the memorydevice 1906, or the conductors 1908 can optionally be covered orconformally encapsulated with a non-conductive protective layer, such asa film, an epoxy, an insulator, or other non-conductive material toprotect the electronics and the flexible conductors from damage. Theelectrical components 1910 can be mounted on the first end panel 102 orthe second end panel 104.

Referring now to FIG. 20, therein is shown a cross-sectional view ofFIG. 19 taken along a line 20-20 of FIG. 19. The foldable electricalconnector-housing system 100 can, for example, include the first endpanel 102 with the controller 1902, the memory timing control module1904 of FIG. 19, the memory device 1906, a substrate 2002, and the firstend panel contacts 114.

The substrate 2002 such as a thin film, a thick film, a printed circuitboard, or a flex type board, can provide mounting and connectivity forthe memory circuitry and the first end panel contacts 114. Optionally,the controller 1902, the memory timing control module 1904, the memorydevice 1906, or the first end panel contacts 114 can also be mounteddirectly to panels and electrically connected with the flexibleconductors.

For example, flexible circuit boards are a means of creating a thinmedium for mounting the controller 1902, the memory timing controlmodule 1904, the memory device 1906 and the flexible conductors can beused to connect the controller 1902, the memory timing control module1904, the memory device 1906, or the substrate 2002 on two or morepanels.

For purposes of illustration, the first end panel contacts 114 are shownprotruding beyond the outer first end panel side 112 of the first endpanel 102 although it is understood that the first end panel contacts114 can be formed in any location, orientation, or relative position tothe outer first end panel side 112.

Referring now to FIG. 21, therein is shown a cross-sectional view of thestructure of FIG. 20 in a connection phase. A foldable electricalconnector-housing 2102, substantially the same as the foldableelectrical connector-housing system 100 can be connected to a connector2104 such as a female universal serial bus connector (USB connector), auser specific female connector, an enclosure, an assembly, or variouselectronic systems.

First end panel contacts 2114, substantially the same as the first endpanel contacts 114 of FIG. 1 can be fully inserted into the connector2104.

The connector 2104 can preferably fully enclose a portion of thefoldable electrical connector-housing 2102 and substantially enclose thefirst end panel contacts 2114.

The connector 2104 can receive folded panels with the first end panelcontacts 2114 to provide pressure for an interference fit within theconnector 2104. The first end panel contacts 2114 inserted in theconnector 2104 can provide electrical connectivity to a subsystem orsystem.

Referring now to FIG. 22, therein is shown a flow chart of a method 2200of manufacture of a foldable electrical connector-housing system in afurther embodiment of the present invention. The method 2200 includesproviding a first end panel having an outer first end panel side withfirst end panel contacts that substantially span from one edge of theouter first end panel side to an opposite edge of the outer first endpanel side in a block 2202; providing a second end panel having an outersecond end panel side, the second end panel and the first end panel withthe outer second end panel side facing away from the outer first endpanel side and the first end panel contacts exposed in a foldedconfiguration in a block 2204; mounting electronic components betweenthe outer first end panel side and the outer second end panel side in ablock 2206; and connecting a conductor to the first end panel contactsand the electronic components in a block 2208.

The resulting method, process, apparatus, device, product, and/or systemis straightforward, cost-effective, uncomplicated, highly versatile andeffective, can be surprisingly and unobviously implemented by adaptingknown technologies, and are thus readily suited for efficiently andeconomically manufacturing package in package systems/fully compatiblewith conventional manufacturing methods or processes and technologies.

Another important aspect of the present invention is that it valuablysupports and services the historical trend of reducing costs,simplifying systems, and increasing performance.

These and other valuable aspects of the present invention consequentlyfurther the state of the technology to at least the next level.

While the invention has been described in conjunction with a specificbest, it is to be understood that many alternatives, modifications, andvariations will be apparent to those skilled in the art in light of theaforegoing description. Accordingly, it is intended to embrace all suchalternatives, modifications, and variations that fall within the scopeof the included claims. All matters hithertofore set forth herein orshown in the accompanying drawings are to be interpreted in anillustrative and non-limiting sense.

What is claimed is:
 1. A data storage device comprising: storagecircuitry configured to store data; a substantially planar cardcomprising a first portion, an additional portion, a guide marking aboundary between the first portion and the additional portion, and thestorage circuitry; an electrical interface electrically connected to thestorage circuitry and located on a first face of the first portion ofthe card; and wherein the card is configured so that if the firstportion is folded along the guide with respect to the additional portionso that the portions are directly below the electrical interface, andthe first portion and the additional portion are parallel to each other,the combined thickness of the first portion and the additional portionis sufficient to make contact with both an electrical interface of acommunications receptacle and a shell portion of the communicationsreceptacle when the folded card is inserted into the communicationsreceptacle.
 2. The device of claim 1 wherein the standard electricalcommunications receptacle is a USB receptacle.
 3. The device of claim 1wherein the combined thickness is:CT=(1+N)*MT where: CT=the combined thickness, N=the number of folds, andMT=the material thickness of each portion.
 4. The device of claim 1wherein the combined thickness is at least 2 mm.
 5. The device of claim1 wherein the first portion and the additional portion comprises anon-conductive material.
 6. The device of claim 1 wherein the firstportion and the additional portion each has substantially the samethickness.
 7. The device of claim 1 wherein the guide extends along alongest dimension of the card.
 8. The device of claim 1 wherein theguide extends along a second longest dimension of the card.
 9. A datastorage device comprising: storage circuitry configured to store data; asubstantially planar card comprising a first portion, one or moreadditional portions, a guide marking a boundary between the firstportion and at least one of the one or more additional portions, and thestorage circuitry; an electrical interface electrically connected to thestorage circuitry and located on a first face of the first portion ofthe card; and wherein the card is configured so that if the firstportion is folded along the guide with respect to the at least one ofthe one or more additional portions so that the one or more portions aredirectly below the electrical interface, and the first portion and theone or more additional portions are parallel to each other, the combinedthickness of the first portion and the one or more additional portionsis sufficient to make contact with both an electrical interface of astandard electrical communications connector and a shell portion of thestandard communications connector when the folded card is inserted intothe standard communications connector.
 10. The device of claim 9 whereinthe standard electrical communications connector is a USB connector andthe first portion and the one or more additional portions form afoldable electrical connector-housing system that is sized to makecontact with both an electrical interface portion of a USB connector anda shell portion of the connector when the foldable electricalconnector-housing system is inserted into the connector.
 11. The deviceof claim 9 wherein the card comprises a plurality of regions for foldingthe first portion and the one or more additional portions.
 12. Thedevice of claim 9 wherein the data storage device is connectible to anon-conductive, substantially planar carrier.
 13. The device of claim 9wherein the card comprises a first portion and a substantially planarcarrier laminated together and the storage circuitry compriseselectronics printed on at least one of the first portion and thesubstantially planar carrier using a flexible conductor.
 14. The deviceof claim 9 wherein the card comprises a first portion and asubstantially planar carrier laminated together and the card furthercomprises storage circuitry including a memory device positioned betweenthe first portion and the substantially planar carrier.
 15. A datastorage device comprising: storage circuitry configured to store data; afirst substantially planar card portion comprising the storagecircuitry; an electrical interface electrically connected to the storagecircuitry and located on one side of the first card portion; one or moreadditional substantially planar card portions positioned below the otherside of the first card portion and positioned parallel to one anotherand parallel to the first card portion; and wherein the combinedthickness of the first card portion and the one or more additional cardportions is sufficient to make contact with both an electrical interfaceof an electrical communications receptacle and a shell portion of thereceptacle when the first card portion and the one or more additionalcard portions are inserted into the communications receptacle.
 16. Thedevice of claim 15 further comprising the first portion covering the oneor more additional portions and keeping the first portion and the one ormore additional portions in parallel with one another.
 17. The device ofclaim 15 further comprising the first portion encapsulating the one ormore additional portions and keeping the first portion and the one ormore additional portions in parallel with one another
 18. The device ofclaim 15 wherein the electrical interface comprises a flexibleconductor.
 19. The device of claim 15 wherein the electrical interfaceis configured to allow the data to be read from storage circuitry. 20.The device of claim 15 wherein the storage circuitry comprises a memorydevice.